Just because a piece of equipment functions doesn’t mean a shop should keep using it. Mast Motorsports realized that a couple machine tools at its Walled Lake, Mich., facility had become technologically obsolete and, therefore, needed to be replaced. The Nacogdoches, Texas-headquartered company manufactures automotive components, such as cylinder heads, intake manifolds and induction systems, for street performance and racing. Mast primarily machines aluminum and plastic.
After researching suitable replacement machines from Hurco North America at a trade show and considering similar offerings from other machine tool builders, Mast purchased two Hurco 5-axis CNC milling machines: a VMX60SRTi and a VMX42SWi. “The best replacement was the configuration Hurco had to offer,” said Cary Chouinard, director of manufacturing at Mast.
According to Indianapolis-based Hurco, the machines are configured to use a swivel head with either an A- or C-style rotary table. The rotary table measures 66"×26" (1,676.4mm × 660.4mm) and enhances versatility because it can provide extra table space for secondary operations or 3-axis work.
Chouinard also appreciates that the milling machines’ controls allow additional work to be performed at the machines. “The whole manual for operating the machine and everything that you want to know is right at the controller,” he said.
In addition, programming the machines isn’t a challenge. “Whether you’re using G and M codes or manually programming them, it’s very simple,” Chouinard said.
Compared to Mast’s outdated equipment, the Hurco machines are almost twice as fast, according to Chouinard. He added that Mast has been able to decrease machining time while reducing the step-over and producing more consistent and higher-quality parts. “The cost savings have been huge,” Chouinard said.
Although the quickness of the machines enables aggressive cutting, Chouinard noted the machines, which have a peak spindle motor horsepower of 48 hp (36.5kW) at 2,900 rpm, are quiet enough so that he can hear what is happening throughout the 7,500-sq.-ft. shop.
“It’s more advantageous for us to run with one line of machines,” Chouinard said, “so we’re trying to go with all Hurco equipment here.”
Read the full story from Cutting Tool Engineering here
Watch The Video From IMTS 2016
At 33, Eric Medlen was a rising star in the NHRA drag racing circuit, winner of six tour events, eight times a number one qualifier, he was a media favorite for his running commentary, and a fan favorite for both his accessibility and his enthusiasm. Medlen’s path to drag racing wasn’t typical. As a high school rodeo champion and calf roping protégé to two-time PRCA World Champion Jerold Camarillo, he was planning to join Camarillo’s team when his dad, John Medlen, called with the job he had always dreamed of: working alongside him at John Force Racing.
After eight years as a JFR crew member, Eric got the chance of a lifetime: team owner John Force chose Eric to replace JFR driver Tony Pedregon, who left JFR to form a new team with his brother at the end of the 2003 season. According to JFR, Eric said at the time, “My dad was my hero growing up and I always dreamed that we’d wind up racing together, but I never dreamed that I’d be driving and he’d be the crew chief on the same car, especially at a place like John Force Racing.”
John Force threw his complete support behind the project by opening a state-of-the-art machine shop at the team’s newly built 180,000-square-foot facility in Brownsburg, Indiana. Eric’s father, John Medlen, became project manager of the Eric Medlen Project and worked with Ford Motor Company, the NHRA, SFI, chassis builder Murf McKinney and a host of others in an unprecedented display of cooperation.
Ironically, John Force was the first driver to benefit from the initial changes that were made to the chassis as part of the Eric Medlen Project. Although Force broke bones in his hands and feet when he crashed at Ennis, Texas, in September of 2007, he had no serious head or neck injuries.
The improvements that made Force’s survival possible included a wider roll cage, extra padding within it, the switch from five-point to seven-point harnesses and a head-and-neck restraint system that limits side-to-side movement as well as front-to back.
Fast forward to 2016, and the Force American Made employs 24 out of JFR’s approximately 100 employees. The 7 machine shop employees operate the team’s 17 CNC machines, with the latest additions to the fleet being six Hurco CNC machines: a 3-axis VMX30i , a 5-axis VMX42SRTi, a 3-axis VMX6030i, TMX8MYSi mill turn slant-bed lathe, and two TMM8i slant-bed lathes with live tooling.
Dean "Guido" Antonelli, General Manager of Force American Made, said,
“When we evaluate machines to replace existing equipment, I am always looking to improve tolerances and spindle speed as well as expand the shop’s capabilities and find ways to increase efficiency. Our tolerances are in the ten-thousandths, which means accuracy and repeatability are critical when it comes to the CNC machines we select.”
Antonelli said the Hurco CNC machines have outperformed his expectations. Antonelli and Nic Barnes, the Machine Shop Supervisor, said the benefits they appreciate the most from the new Hurco CNC machines are the surface finish quality, fast rapids, rigidity, accuracy, the robust technical specifications of the Hurco control, the swing-arm ATC design and tool capacity, and the productivity gains from adopting 5-sided machining for parts they used to manufacture on 3-axis machines.
“We’re always looking to improve the quality and strength as well as the fit and the finish of the parts we make. With the Hurcos, the finish is like jewelry. I don’t even have to polish the parts,” said Barnes.
The impressive surface finish quality is due to the motion control system Hurco invented. Named UltiMotion, the patented motion control system is software driven and consists of millions of algorithms working in the background to provide optimized look-ahead.
Available on all Hurco 3-axis and 5-axis mills, the user doesn’t have to do anything to make UltiMotion work. While the technology is complex, there is no setup or configuration required. In addition to delivering superb surface finishes, UltiMotion also reduces cycle time by up to 35%, and sometimes more, because it minimizes machine jerk and evaluates the part geometry to calculate the optimal lookahead (up to 10,000 blocks).
The team uses MasterCAM to create the majority of its part programs, which Barnes and Antonelli said is another advantage of selecting Hurco CNC machines. “We’ve always heard about the Hurco control being really good at conversational programming, but what we’ve found is that it’s true when they say it is the most flexible control in the industry. It processes G-code better than any of the machines we’ve had in the past,” said Antonelli. The technical specifications of the Hurco control that eliminate the hassle the FAM shop experienced in the past with other controls include a 2.7GHz Dual Core Processor, 4GB RAM Memory, and a 128GB Solid State Hard Drive, and up to 4,000 bps processing speed.
“It’s a big deal,” Barnes said of the memory and speed with which the Hurco control loads part programs. “We have a flywheel part with two operations that we separated into two part programs because it would take 52 minutes just to load one operation before we got the Hurco. But now, with the Hurco control, it takes 10 seconds.”
“And the memory is so great we can have multiple programs loaded instead of loading them one at a time,” said Barnes. The graphics display, called Advanced Verification Graphics, is another winning feature of the Hurco control, according to Barnes. “It just gives me peace of mind to know I can see the detail of what the tool is doing and know there aren’t any crashes. The display is really clear and offers different views on the DRO.”
However, the biggest advantage the team has seen in terms of productivity has been the decision to embrace 5-sided machining on 5-axis machines, a trend that is becoming the norm in shops of all sizes across the nation.
“On our fuel distribution blocks, we went from six operations to two. With six ops, the part took a total of six hours and on the 5-axis machine it takes four hours,” said Barnes.
Not only does the adoption of 5-sided save setup time since the machinist doesn’t need to manually flip parts and then fixture them again for each operation, machining time is decreased.
“On the main cap, we went from 22.5 minutes of machine time on the 3-axis machine to just 16 minutes,” said Barnes.
As the JFR manufacturing team looks to the future, they continue to honor the life of not only Eric Medlen but all drag racers who have lost their lives and challenge them to continuously evaluate ways to improve safety on the race track. Hurco is proud to be a part of such an important mission and a proud sponsor of John Force Racing.
Aerodyne Precision Machining Inc. (APM) incorporated thirty years ago in Southern California’s Surf City, Huntington Beach, California. What started out as a home based company in Raymond Krispel’s garage has grown into a 20,000 sq.ft. manufacturing facility with 32 employees and well over a dozen CNC milling and turning centers.
APM is one of the larger Hurco shops in Southern California, and just made the jump to 5 axis machining three years ago. “We’ve been dealing with Machinery Sales for a couple years,” explains Eric. “Garry Frost, his sales staff and service team do a great job supporting the Hurco product line, but it took us a while to finally pull the trigger on our first 5 axis.” After seeing it run at an open house, APM ordered a Hurco VMX42U. It is a 24hp machine with 40 tools and Hurco’s integrated trunnion table. “Combined setup and training was less than two weeks,” adds Ben. “We were cutting chips on actual jobs before the training crew even left.” APM discovered that the 5 axis not only changed the way they machined parts, but also how they looked at jobs. “We are taking a part that used to have 8 operations and now only two at most,” explains Eric. “Besides the time savings we have seen a huge bump in overall accuracy.
Aerodyne Precision Machining (APM) credits Hurco and its extensive product line as being an integral part of their success. APM has been a Hurco customer for many years, but just purchased their first 5-axis CNC machine three years ago after seeing a cutting demonstration at Machinery Sales Company’s open house. With their new Hurco 5-axis machining center, APM reduced the number of operations on just one part from 8 to 2. The programmers all love the Hurco control, specifically the user friendly quality, and say the Hurco control is one of the biggest selling points of the machines.
Read the full article by Sean Buur published in the March 2016 issue of CNC West Magazine
Photos by Sean Buur & Aerodyne
Robbie Ott, the head machinist at CFH Racing runs the machine shop. He discussed the transition to Hurco machines after we installed our flagship Hurco VMX42i mill and a TM8i lathe. Ott also elaborated on the possible benefits he expects when the shop adds the Hurco VMX42SRTi 5-axis machine.
"I especially like using the Hurco when building prototypes. Just recently we built prototype damper parts. And like with most prototypes, we did not succeed the first time. Hurco gave us the flexibility to make modifications quickly and easily without starting from scratch.Hurco and HSM Works solid modeling allowed us to build these extravagant and complicated parts that would not have been possible on the manual machine," concluded Ott.
An article in Engieering Capacity features Hurco customer RP Tooling, a company focused on toolmaking with 50% of their parts being used for vehicles such as the Range Rover Sport, Audi R8 Etron, F-Type Jaguar and the Ford Ranger. The other half of RP Toolings molds could be components anything from medical equipment to lawn mowers to boilers.
RP Tooling's owner says that a new feature in the Hurco software on the latest machines, called Ultimotion, reduces cycle times by up to 30 per cent. UltiMotion was invented by Hurco and includes software-based look-ahead, which uses an advanced algorithm within WinMax to evaluate the component geometry and motion profile of the cutting cycle to optimise and smooth the tool paths.
The company finds UltiMotion especially beneficial when profiling complex features, reducing manufacturing costs and allowing more competitive prices to be quoted. So great are the advantages that all of RP Tooling’s Hurco controls will be updated this year with the new software.
RP Tooling currently has 11 Hurco 3-axis machining centers and one Hurco 5-axis machining center.
Read the full article.
Image copyright © Mercator Media 2015
Lou Ferriero was working in a plastics vacuum forming house when he identified a market that wasn’t being served. When he started PlasTech Machining and Fabrication Inc., he had one employee (himself) and one manual machine. Today, PlasTech has nine employees, six vertical machining centers, one 5 axis machining center, three turning centers, and Ferriero is thinking about upgrading to a multi-tasking turning center with live tooling and a sub-spindle.
With more than 35 years of experience in the machining and fabrication of plastics, Ferriero is proud that 80 percent of PlasTech’s business is from repeat customers. Approximately 50% of his business is devoted to medical equipment.
“We focus on high quality and precision. We don’t waste time trying to be the cheapest machine shop out there. Our prices are usually in the middle of the road compared to our competitors. We are the best at what we do and pride ourselves on delivering quality parts on time.” It appears PlasTech’s focus on quality versus price is working. According to Ferriero, companies that shipped jobs overseas for cheaper rates have started bringing the business back to PlasTech. “We lost jobs to overseas suppliers about five years ago and most of that work has come back,” said Ferriero.
A big part of PlasTech’s success is due to Ferriero’s commitment to stay current with technology by investing in new equipment. As PlasTech has grown, so has his investment in Hurco machine tools and Hurco technology. His latest investment in a Hurco software feature called UltiMotion continues to provide benefits beyond Ferriero’s expectations. As an example, Ferriero cites a part used for head restraints on hospital beds. “When we machined the parts on our RoboDrill, it took 30 minutes per part. On our Hurco with UltiMotion, it takes 20 minutes and the surface finish quality improved significantly,” says Ferrierro.
UltiMotion is able to simultaneously decrease cycle time and increase surface finish quality due to the underlying motion control algorithm Hurco developed that uses software-based motion instead of conventional hardware-based motion. UltiMotion software has rapid cornering capabilities that allow the spindle to travel through corners at high speed with negligible deviation without overshooting or stopping. Therefore, cycle time is significantly reduced when machining parts with complex geometries and/or repetitive tasks, such as drilling and tapping. Customers with UltiMotion also see improvement in surface finish because UltiMotion minimizes vibration, which results in smoother motion overall.
Flexible Control that Supports NC and Conversational
While PlasTech finds the conversational programming of the integrated Hurco control extremely useful to quickly make a fixture, Ferriero says he uses the NC side of the control for all of his jobs. Keeping his CAM system current is another technology investment that Ferriero continually makes to keep his company up to speed. PlasTech uses Mastercam X5 Cad /Cam software with Mill Level 3 and solids, Mastercam Lathe, verification software, Solidworks, and E2 Shop Systems for shop control.
The Power of Five
Like many prudent job shop owners, Ferriero’s latest machining center investment was a Hurco VM10U 5-axis machining center instead of a traditional 3-axis machine. The VM10U is part of the integrated trunnion style 5-axis machines from Hurco. With X/Y/Z travels of 21x16x19 and a 20-station ATC, the VM10U is one of the highest value 5-axis machines on the market.
Ferriero bought the VM10U to cut down on setups and has realized numerous productivity benefits. "The Hurco VM10U has exceeded our expectations. It has cut down on cost, time, labor and material," said Ferriero.
He cited a specific example for an article that appeared in Manufacturing News. The job entailed the manufacture of plastic components for prototype parts for de-icing the C-130 aircraft. "Without the VM10U 5-axis machine this would have been nearly impossible to get done on time for our customer," said Ferriero. "After offline programming, the setup time on the machine was done in a few hours. The part surface quality and time comparison was much better than expected. It would have been a minimum of 2 days just to make fixtures to machine these parts on a 3-axis machine."
Beyond the technology, beyond the equipment, Ferriero says he continues to invest in Hurco machining centers because of the high quality service he gets from Hurco and Hurco’s distributor, Brooks Associates. Says Ferriero, “The service we get from Hurco and Brooks is second to none. They listen and they are responsive. They understand that your machines are your business.”
Click this link to read the article about PlasTech that appeared in Manufacturing News.
During the last 30 years, Injection Mold, Inc. (North Vernon, Indiana) has grown from a small garage shop dedicated to producing lens molds for the automotive industry to a full-service shop that that specializes in Rapid Prototyping (RP) molds for multiple industries, such as medical, electronics, safety, baby products, appliance, and plumbing. A desire to reduce set-up times and increase accuracy led the company to upgrade from three-axis to five-axis machines.
According to General Manager Jason Vawter, Injection Mold has a stellar reputation when it comes to speed. “Customers call us immediately when they need something quick, without even considering their other suppliers, because we are the quickest," he says. This need for speed led Injection Mold to consider upgrading from three-axis to five-axis technology. “A lot of our RP work involves multiple setups on three-axis machines, and with the short deliveries we do, we needed to find a way to speed up our times,” Vawter explains. “Using five-axis technology would allow us to eliminate a lot of set-ups.”Vawter looked at a number of different machines, but all roads led to Hurco. “One of the reasons we went with Hurco is that they are right down the road from us,” he says. “We also owned Hurcos in the past and have been very happy with them. We found that the VMX30U was exactly what we were looking for.” Hurco decided to make 5-Axis a priority 10 years ago and has dedicated resources to the development of features that make the transition easy for 3-axis shops. Hurco even started a website devoted to five-axis education (www.FiveAxisMachining.com) that includes a dedicated telephone number and email that goes directly to Hurco Applications Engineers with expertise in 5-axis/5-sided. The VMX30U that Injection Mold purchased is one of 11 Hurco 5-Axis machining centers that are the result of Hurco’s focus on 5-axis. While the transition from 3-axis machining to 5-axis can be intimidating, most machinists grasp the concept fairly quickly and continue to realize additional benefits the more they use the machine. “Five-axis was a brand new area for us,” Vawter recalls. “Since we have always had three-axis, we grew accustomed to working in three planes. Then, all of a sudden, there were five.” While he says it took the employees several months to get completely comfortable with the machine, Hurco was always readily available to field questions.Multiple AdvantagesInjection Mold bought the machine solely for the purpose of eliminating multiple set-ups, but Vawter notes the more they use the VMX30U, the more they find they can do with it. “For example, we had some slides (multicavity tool with multiple slides per cavity) and they have angled holes through them on 20 degrees,” he elaborates. “There’s a 25-degree angle on the back with tapped holes. To machine these in the past, we would have one set-up for each operation on a 3-axis mill and it would have taken probably five set-ups with an hour to an hour-and-a-half on each block. When we do it on the VMX30U, it is one set-up and 20 minutes in each piece.”Another payoff is higher accuracy. “Each time you have to take the piece out of the machine to put in another setup, you take a chance of everything not blending out,” he explains. “Now we just pick it up one time and we will cut from the top and the machine will rotate and cut the piece from the side—so accuracy is better. We maintain .005 micron accuracy on our work.” Vawter is very pleased with the VMX30U. “Once we made the leap, we continue to find more benefits—things we didn’t even consider are now possible. We have had it a little over a year and we feel like we are just starting to scratch the surface of what we can utilize it for. We will definitely consider another five-axis purchase by year’s end.”Injection Mold, Inc. / (812) email@example.com / injectiomoldinc.com
Click this link to read the article about Injection Mold as it appeared in MoldMaking Technology Magazine
"The Hurco control makes it easy to get the part from my head to the control.”
Shane Sievers, Lead Machinist, Dreyer & Reinbold Racing, Indianapolis, USA
In racing, there are millions of things that happen before the driver even gets in the car that make a race team more competitive. As Dreyer & Reinbold Racing geared up for the 2011 season, they looked to their machine shop for a competitive edge. The Hurco 5-axis VMX42SR and mill-turn TMX8MYS were installed at their 35,000 square foot facility in Indianapolis in March of 2011.
“We never know what’s coming next....which is a lot like a job shop environment,” says Shane Sievers, the lead machinist at DRR. Sievers started machining back in the days of punch tape and has run numerous brands of CNC machines. He had always run G-code until Hurco.
“I truly love these machines. Being able to program at the machine is my favorite thing. With the VMX42SR, I can do 5-axis [5-sided] work without having to use the CAM system or G-code. Transform Plane is the feature that makes it easy,” says Sievers.
Another reason the Hurco CNC machines are perfect for the race team’s shop is the ability to minimize setup time. “50 parts is a big run for us so it’s important to have a machine that reduces setup time,” says Sievers. The 5-sided process on the VMX42SR, Sievers eliminates three setups on just one part, which saves him at least 30 minutes per part.
“In a lot of ways, we’re like a prototype shop. I’ll get a call when the team is on the race track and they’ll say they need a new part tomorrow morning. Sometimes I have a print. Sometimes I sketch it out on a piece of paper. The Hurco control makes it easy to get the part from my head to the control. That’s what I love about being a machinist for an IndyCar team. No day is ever the same. And our Hurcos are made to handle that kind of quick turnaround and the need for constant flexibility.” Even though Sievers says he loves both the VMX42SR and TMX8MYS, he does have a favorite that he thinks might surprise some people.
“If they made me choose, I would choose the TMX8MYS lathe with live tooling. This last software upgrade has been a game changer on the lathe. The verification graphics are phenomenal and the control just makes everything so easy.“
Read how this sub-contractor reduced machining time from 60 minutes to 8 minutes by switching from 3-axis to 5-axis.
The installation of two new Hurco machining centres has allowed Lancashire subcontractor, A&G Precision, to attract more work and produce components more efficiently in fewer set-ups.
The company is a leading producer of complex components used in key military and civil aircraft programmes. It is also active in other sectors, principally defence, marine, petrochemical, motorsport, rail and pharmaceutical engineering.In addition to batch production of high-precision components, A&G provides a range of additional services including prototyping, sub-assembly manufacture and reverse engineering.
There are a number of purpose-built 5-axis / 5-sided machining centre designs on the market, including types with a rotary table and either a trunnion support or a swivelling B-axis head to provide the fifth CNC axis. A number of companies including Hurco supply such machines, but neither configuration suited Brunswick Tooling, Brighouse, a manufacturer of reamers and special cutting tools, both solid carbide and indexable-insert.
“I have built my business by attracting top-notch machinists and then giving them the tools to put their talents to work. I have found that the capabilities of Hurco machining centers to do complex, high accuracy work is perfect for my operation.”
As part complexity grows, Mike can see the need for 5-axis machines to efficiently produce multi-sided parts in one setup. Hurco’s control is 5-axis capable and its vertical machining centers can be equipped with a variety of precision tables.
If a fully integrated solution is required, Hurco has high performance vertical machines with an integral trunion table, which is perfect for processing complex high-precision work in one set-up.
With a BP quality award hanging on its office wall alongside a platinum award from Cameron Subsea Systems confirming 24 consecutive months' delivery of zero defect products, Blantyre-based Quadscot Precision Engineers is a leading Scottish subcontractor serving the offshore oil and gas sector.
For its prismatic machining requirements, until recently the company relied on 3-axis vertical machining centres (VMCs) including a Hurco VMX1 installed in 2008 and a 12-year-old VMX42 with Nikken 4th axis. As part of an on-going investment programme in new plant, two further, larger VMCs were purchased from the same supplier at the beginning of 2010. The objective was to bring the subcontractor's milling capacity more into line with its 1.5 metre by 500 mm diameter turning capability. One of the new Hurcos, Quadscot's first 5-axis model, was a VMX60SR. It has a 1,525 x 660 x 610 mm working volume, a horizontal rotary C-axis table and a ± 92 degree B-axis head that allows the 36 kW, 40-taper spindle to be positioned within a program anywhere between vertical and horizontal. Renishaw tool and part probing have been fitted to speed set-ups.
Founded in 1987 as a mouldmaker and subcontract machinist specialising in wire and spark erosion and manual milling, RST Engineering, Leighton Buzzard, installed a Hurco Hawk 30 CNC mill in 1998 to speed electrode production and other prismatic machining jobs. It was not until 2007 that the company traded in the Hawk for a 3-axis Hurco VM2 vertical machining centre, taking advantage of automatic tool change to fulfill contracts more economically for increasingly complex aerospace, medical and motorsport components. Two years later, owner Jason Taylor and his team progressed to 5-axis machining on a Hurco VMX30U machining centre, with very positive results. It was bought initially to reduce production costs when the manufacture of prototype housings for aircraft on the VM2 moved to large batch runs.
When BAW Precision Engineering Ltd emerged from the global downturn under new ownership in July 2010, the primary aim for the new directors of the Swansea Valley company was to build the order book and re-establish the subcontractors’ prestigious reputation.
Parts for instrumentation used in space observation, both terrestrial and satellite-based, are machined to tight tolerances on two Hurco vertical machining centres (VMCs) at Rutherford Appleton Laboratory (RAL), near Didcot.
A steady increase in subcontract work for the medical industry coupled with the trend towards greater component complexity has prompted Caragh Tool & Die to invest in a fifth Hurco machining centre with 5-axis capability. Off-line programming has also been installed to simulate the proprietary Ultimax twin-screen control system fitted to all of the machines.
Seven vertical machining centres from the same supplier, HURCO Europe, have been installed during the past 10 years in the Witney, Oxfordshire works of Acrona Engineering, including most recently a 5-axis VM10U with WinMax control purchased at the beginning of 2010.
The people at NuCon Corporation are experts when it comes to impellers. More specifically, they are experts in the manufacturing of radial and axial compressors, pumps and turbines, shrouded impellers, expanders, diffusers, and jet engine cases. They’re also experts in 5-axis machining processes used to manufacture those impellers and the aforementioned parts.
Since 1973, NuCon Corporation has used their proprietary Impeller Machining System to machine thousands of configurations as small as 5 mm in diameter up to 73 inches in diameter. The majority of their products are used for marine propulsion and pumps, industrial compressors, and power generation, but they also machine parts for aircraft and rocket engines. NuCon primarily machines stainless steel, but they have experience machining a variety of materials including aluminum, titanium, exotics, and plastics. They can do any blade configuration a customer needs including straight line element, arbitrary blade shape, blisk, an open or shrouded impeller, and an open or closed turbine. Different blade shapes within a single stator/rotor can be accommodated.
NuCon primarily relies on 15 vintage Sundstrand 5-axis machining centers at their 35,000-square-foot facility in Livonia, Michigan to manufacture these complex blade configurations for customers around the world. In fact, there are only a handful of companies capable of serving this niche market. The NuCon crew has upgraded, retrofitted, and refurbished the massive Sundstrand machining centers so they can handle large parts that vary in complexity and weight, with some blanks weighing as much as 11 tons.
Co-owner David Bernhardt says he started shopping for a smaller 5-axis machining center because it didn’t make sense to tie up a large Sundstrand for smaller parts that were up to 22 inches in diameter. While he considered other brands of 5-axis machines, Bernhardt says a demonstration at Hurco’s technology center in Indianapolis sealed the deal and NuCon purchased two VMX42SR machines. “The VMX42SR’s table had the capacity to handle the weight of stainless steel, which is important because that’s the material we use the most,” explains Bernhardt. The VMX42SR’s C-Axis table with a 24-inch diameter can handle up to 1,100 lbs and the machining center is designed with a B-axis swivel head and C-axis rotary table that lets the tool access hard to reach areas faster. The tilting head design is perfect for the swept surfaces and complex contours NuCon routinely machines. Other advantages of the Hurco VMX42SR include 600-block look ahead, up to 600 ipm programmable feed rate, and processing speed up to 2,277 bps.
Hurco was especially honored that NuCon chose Hurco for its 5-axis machining needs of smaller parts considering the collective expertise of the owners and the exacting standards they demand. NuCon owners David Bernhardt and David Stormont know machine tools inside and out: literally. They were machine tool designers in the 60s at the Buhr Company in Ann Arbor, Michigan, a company well known for developing machine tools designed specifically for the automotive industry. Because of the collective expertise of Bernhardt and Stormont, NuCon has successfully developed their proprietary Impellar Manufacturing Software, designed the spindle head for their rotary head machines, and created their own PC-based controllers. They have achieved accreditation for numerous quality programs and implemented verification and inspection programs throughout their operation.
Bernhardt says he is enamored with the motion control on the Hurco and both VMX42SRs have performed perfectly. Beyond the machine, Bernhardt says the phenomenal service network Hurco has established is probably the best he’s seen in his career. “It’s really something you should promote. The knowledge and customer support is outstanding. I even sold a machine to a fellow down the road. He asked me about our Hurcos and I told him about the phenomenal service network you have and the outstanding performance of our machines. This is still an industry that relies on word-of-mouth, which means a company’s reputation for how they treat customers after they have bought the machine is important,” explains Bernhardt.
While Hurco machine tools are often known for their intuitive conversational programming, NuCon uses the NC side of the control exclusively. The integrated Hurco control powered by WinMax includes both conversational and NC programming methods with ISNC and NC Productivity Packages available for enhanced performance. With an enhanced NC interpreter, the recently released WinMax version 8 (WinMax8) is compatible with more CAD/CAM programs than ever. Other additions to the NC side of the control include Tool Review, Transform Plane, Rotary Tangential Velocity Control, Automatic Safe Repositioning, Recovery Restart, and Cylindrical Wrap.
“It really says a lot for us to go to another machine with an alien control when all of the Sundstrands and turning systems we have use the control system we developed. The integration has been seamless and all of the operators picked up the Hurco control quickly,” says Bernhardt.
NuCon also invests in other technology to enhance efficiency, minimize waste, and maintain outstanding quality. Bernhardt says software packages from OpenMind and Predator are useful to his operation because they analyze part programs to achieve maximum machining efficiency.
Bernhardt attributes his company’s success to great customers, great employees, and the drive to continually find ways to increase efficiency while maintaining the highest quality. “The core of our manufacturing philosophy at NuCon has always been to satisfy our customers. The job isn’t finished until the customer requirements are met. We believe in continual process improvement. You always need to look for ways to work smarter even while you’re working harder,” says Bernhardt.
For NuCon, purchasing the Hurco VMX42SRs helped the company work smarter for smaller 5-axis parts.
NuCon34100 Industrial RoadLivonia, MI 48150734.525.0770www.nuconcorp.comHurco Companies, Inc.One Technology WayIndianapolis, IN 46268800.634.2416www.hurco.com
Because of Hurco’s track record of developing technology that increases productivity and for manufacturing rigid machines that last, EMM Precision purchased a Hurco 5-axis VM10U. Keith Dalpe, vice president, says the machine was purchased specifically for a new contract that EMM Precision won for a military part. Regarding the VM10U 5-axis machining center, Keith says, “Everybody loves it. It’s just unbelievable what this machine does.
“To stay competitive in the stamping die business, we had to address setup time on multi-sided parts. Our new Hurco VTXU has slashed overall processing time on many parts by 70%. Not only that but it can cut! I run out of tool before I ran out of machine.”-Dave W. Rose, Vice President